EP1276610B1 - Absorbent sheet material having cut-resistant particles and methods for making the same - Google Patents

Absorbent sheet material having cut-resistant particles and methods for making the same Download PDF

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Publication number
EP1276610B1
EP1276610B1 EP01932655A EP01932655A EP1276610B1 EP 1276610 B1 EP1276610 B1 EP 1276610B1 EP 01932655 A EP01932655 A EP 01932655A EP 01932655 A EP01932655 A EP 01932655A EP 1276610 B1 EP1276610 B1 EP 1276610B1
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EP
European Patent Office
Prior art keywords
sheet material
sheet
particles
absorbent
recited
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP01932655A
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German (de)
English (en)
French (fr)
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EP1276610A2 (en
Inventor
John Kit Carson
Steven Michael Schennum
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Procter and Gamble Co
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Procter and Gamble Co
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Publication date
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Publication of EP1276610A2 publication Critical patent/EP1276610A2/en
Application granted granted Critical
Publication of EP1276610B1 publication Critical patent/EP1276610B1/en
Anticipated expiration legal-status Critical
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/08—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • B29C48/08—Flat, e.g. panels flexible, e.g. films
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/91—Heating, e.g. for cross linking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/16—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer formed of particles, e.g. chips, powder or granules
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
    • Y10T428/253—Cellulosic [e.g., wood, paper, cork, rayon, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
    • Y10T428/254—Polymeric or resinous material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/27—Web or sheet containing structurally defined element or component, the element or component having a specified weight per unit area [e.g., gms/sq cm, lbs/sq ft, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31—Surface property or characteristic of web, sheet or block

Definitions

  • the present invention relates generally to sheet materials which are cut-resistant, shred-resistant, and absorbent, and methods for making the same. More specifically, in one embodiment, the present invention relates to high basis weight paper structures which include randomly distributed polymer particles locked into the paper structure.
  • protective materials having durability have been used for many applications.
  • protective materials can be used as cutting boards to cover countertops during food preparation, such as when cutting meats or vegetables for cooking.
  • Such protective materials can protect the food item from contacting contaminants which may reside on the support surface, such as a countertop.
  • such a material can also protect the support surface from physical damage from a cutting tool, as well as from contamination from the food item being prepared.
  • plastic materials are high in cut and shred resistance but low in absorbency
  • conventional paper materials are typically high in absorbency but low in cut and/or shred resistance, since paper fibers can be easily released as a cutting tool is drawn over the cutting surface.
  • WO 99/18156 discloses a polymeric sheet said to have excellent cut-resistance comprising a polymeric material and a hard filler.
  • Polymeric fibers have previously been utilized as a binder and strengthening agent in paper structures.
  • fibers made from hydrophobic polymers are added to paper fluff during paper formation.
  • the polymeric fibers flow and coat the surrounding paper fibers locking the paper fibers into the structure and significantly reducing the overall absorbency of the resulting structure.
  • the amount of polymer fiber could be reduced from the mixture to increase absorbency, such a solution compromises the cut-resistance and shred-resistance of the structure.
  • one problem with such structures is that the amount of polymer fibers required to achieve adequate cut-resistance and/or shred-resistance significantly reduces the absorbency of the structure.
  • a sheet material which exhibits good absorbency and also good cut and shred resistance. It is also desirable to provide such a material that is also relatively flexible so as to be readily disposable, and easily dispensed, stored, and manipulated. In addition, it is desirable to provide such sheet materials which, while durable in use, can be economically manufactured so as to justify their disposal after each use.
  • Another object of the present invention is to provide a disposable and protective cutting sheet.
  • Yet another object of the present invention is to provide a sheet material that can be used to slice food items, and which can effectively absorb juice from the food items while simultaneously resisting damage from a cutting tool.
  • a further object of the present invention is to provide a sheet material that is resistant to shredding and can absorb significant amounts of fluid produced by food items.
  • Another object of the present invention is to provide a cut-resistant, absorbent, shred-resistant sheet material that is readily disposable.
  • Yet another object of the present invention is to manufacture a cut-resistant, absorbent, shred-resistant sheet material using conventional equipment.
  • a cut-resistant, shred-resistant, and absorbent sheet material comprises at least 50 percent by weight of an absorbent material.
  • a plurality of cut-resistant particles that have an average size of at least about 100 micrometers are distributed throughout the absorbent material.
  • the sheet material preferably has a basis weight of at least 100 pounds per 3000 ft 2 (163g/m 2 ). It is also preferred that the absorbent material is substantially free of inorganic particulate filler.
  • a method of forming a cut-resistant, shred-resistant, and absorbent sheet material comprises the steps of forming a mixture comprising absorbent fibers, non-fibrous polymeric particles, and water.
  • the polymeric particles have an average size of between about 100 and about 1000 micrometers
  • the absorbent fibers are provided in an amount of at least 50 percent by weight
  • the mixture is substantially free of inorganic filler particulate.
  • the mixture is formed into a sheet which is then dried.
  • the dried sheet has a basis weight of at least 100 pounds per 3000 ft 2 (163g/m 2 ).
  • the sheet is densified using heat and pressure to lock in the polymer particles and to improve cut and shred resistance.
  • an absorbent and shred-resistant sheet material comprising an absorbent substrate and cut-resistant particles dispersed through the absorbent substrate.
  • the sheet exhibits a wet abrasion loss of less than about 400 mg per 100 revolutions and an absorbent efficiency of at least 0.2. It is preferred that the cut-resistant particles have an average size of at least about 100 micrometers. It is also preferred that the sheet has a basis weight of at least 100 pounds per 3000 ft 2 (163 g/m 2 ), that the absorbent substrate is provided in an amount of at least 50 percent by weight, and that the absorbent substrate is substantially free of inorganic particulate filler. Preferably, the sheet material exhibits a cut resistance of at least 30 kgf/cm.
  • FIG. 1 is a plan view of an exemplary sheet material 20 made according to principles of the present invention.
  • the sheet material 20 includes an absorbent substrate 22 and a plurality of cut-resistant particles 24 randomly dispersed throughout the substrate 22.
  • the sheet 20 is of a substantially uniform thickness t, and includes a cutting surface 26 and a second surface 28.
  • the surfaces 26 and 28 are substantially planar.
  • the continuous absorbent substrate 22 may be formed from any material or materials suitable for absorbing and/or containing fluids of interest.
  • suitable materials include materials formed from natural fibers, such as cellulosic fibers or refined cellulosic fibers, and/or synthetic fibers, including hollow fibers and capillary channel fibers.
  • the absorbent substrate 22 could include an absorbent polymeric foam material, an absorbent polymeric gelling material, a hydrogel material, and/or natural starches and gums, for example.
  • Materials of particular interest include cellulosic substrates, such as paperboard, such as are typically used in paper manufacturing.
  • SSK Southern Softwood Kraft
  • NSK Northern Softwood Kraft
  • eucalyptus cellulosic fiber fluff could be used to form the substrate 22.
  • the substrate 22 could alternatively comprise a non-woven substrate, such as can be constructed by entangling synthetic fibers for instance.
  • the absorbent substrate 22 comprises a continuous layer of material.
  • the substrate 22 could comprise a laminate structure having a plurality of layers of the same or differing composition.
  • the absorbent substrate 22 may comprise an absorbent or non-absorbent carrier web that may include an absorbent material.
  • the cut-resistant particles 24 may be formed from any durable material or materials which are substantially resistant to cutting, abrasions, and shredding from cutting utensils used for food preparation, such as kitchen knives for instance. Typical materials which exhibit such properties may be utilized, including those which exhibit a high degree of toughness and a crystalline molecular structure.
  • the cut-resistant particles 24 are made from polymeric materials, such as ethylene vinyl acetate (EVA), high density polyethylene (HDPE), low density polyethylene (LDPE), linear low density polyethylene (LLDPE), polyvinyl chloride (PVC), plastisols, polypropylene (PP), polyethylene teraphthalate glycol modified (PETG), ultra high molecular weight polyethylene (UHMWPE), polystyrene, and/or polyurethanes.
  • EVA ethylene vinyl acetate
  • HDPE high density polyethylene
  • LDPE low density polyethylene
  • LLDPE linear low density polyethylene
  • PVC polyvinyl chloride
  • plastisols polypropylene
  • PETG polyethylene teraphthalate glycol modified
  • UHMWPE ultra high molecular weight polyethylene
  • polystyrene polystyrene
  • polyurethanes polyurethanes.
  • the material utilized for the cut-resistant particles 24 has a low enough melting temperature T m such that it will soften at temperatures which will not cause the substrate 22 to char or burn during the application of heat.
  • T m melting temperature
  • Such a material can thereby be partially bonded to the substrate 22 through the application of heat and/or pressure, preferably during a subsequent process which densifies the sheet material produced during an initial sheet making process.
  • Such a process can also increase the cut resistance and shred resistance of the sheet material.
  • the melting temperature of the particles be less than or equal to about 450° F (232°C)
  • the material used for the particles 24 has a Vicat softening point (using ASTM test D1525) of less than about 185°F (85°C), to allow it to more readily lock or bond to the substrate 22 under relatively low or moderate temperature.
  • One preferred material for use in the particles 24 is the polymer "PETG”, such as, for example, is sold under the tradename EASTAR PETG COPOLYESTER 6763 by EASTMAN CHEMICAL CO, and which has a Vicat softening point of around 185° F (85°C).
  • Such a material has a good cut and shred resistance and also has a relatively moderate softening point to allow it to be more readily locked into the substrate 22 through heat and/or pressure, without charring or burning the substrate.
  • PETG is less hydrophobic than many other thermoplastics, and so the sheet 20 thereby maintains good overall absorbency.
  • Another preferred material for use in the particles 24 is polystyrene.
  • the particles 24 could also comprise compounded polymeric materials.
  • tough inorganic fillers can also be provided in combination with one or more polymers to form the particles 24, in order to reduce the cost of the particles 24 and/or change particle toughness, density, cut-resistance, color, or other property.
  • Suitable fillers include CaCO 3 , talc, and mica, for example.
  • absorbent substrate 22 is substantially free of inorganic free filler particulate.
  • free filler particulate refers to inorganic particles which are not bonded to the absorbent substrate 22 and which merely reside freely within the absorbent substrate.
  • the absorbent substrate 22 is substantially free of organic free filler particulate which is not suitable for contact with food items.
  • Organic free filler particulate does not refer to the absorbent substrate material, such as cellulosic fibers and the like as described herein.
  • substantially free what is meant is an amount no greater than that which would be safe for use of the absorbent substrate in food preparation, or less than an amount in which the filler particulate released during food preparation is noticeable by visual or tactile inspection of the absorbent substrate or food items, or both.
  • tactile inspection what is meant is tactile sensory via the hand, or, with respect to food items, the mouth.
  • 0% of such free filler particulate is added to the substrate.
  • the level should preferably be no greater than about 10%, more preferably no greater than about 5%, more preferably no greater than about 2%, more preferably no greater than about 1%, more preferably no greater than about 0.5%, and most preferably no greater than about 0.1% by weight of the dry sheet.
  • the sheet hereof can be substantially free of free filler particulate if it contains unbonded particulate material, but none of the particulate material is releasable when the absorbent sheet is used as intended (i.e., by placing a food item on the side of the sheet intended to be used for cutting, and cutting the food item while it is on this side of the sheet.)
  • the sheet can be substantially free of filler particulate when it includes unbonded particulate material which is positioned or configured such that little or none is released from the cutting surface during cutting.
  • At least the cutting surface of the sheet material is shred resistant and exhibits a wet abrasion loss (according to the test described below) of less than about 400 mg per 100 revolutions, and more preferably less than about 300 mg per 100 revolutions.
  • the cutting surface of the sheet material exhibits a dry abrasion loss (according to the test described below) of less than about 300 mg per 100 revolutions, and more preferably less than about 200 mg per 100 revolutions.
  • the sheet material 20 can absorb and sequester fluids deposited on the surfaces 26 and 28.
  • relatively large polymer particles 24 are preferably used, rather than smaller polymer fibers which can coat the materials of the substrate 22 during formation of the final sheet, much of the absorbency of the substrate 22 is maintained.
  • the polymer particles 24 do not completely cover or surround materials of the substrate 22, and therefore do not significantly mask their absorbent properties. Accordingly, more polymer 24 can be provided in the sheet 20 without significantly impacting the absorbency of the sheet.
  • the same amount of small polymer fiber has been found to completely disperse through the structure and surround the material of the substrate 20 and lock out much of its absorbency.
  • the polymeric particles 24 are provided in amounts of up to about 50 percent by weight of the sheet 20. More preferably, the particles 24 are provided in amounts of between about 10 percent and about 40 percent by weight, and most preferably in an amount of around 30 percent by weight. It is also preferred that the absorbent material within the sheet 20 is provided in amounts of at least 50 percent by weight, in order to provide good absorbency.
  • the particles 24 are preferably non-fibrous and the average size of the particles used is preferably at least about 100 micrometers. It should be noted that while some particles may have sizes below 100 micrometers, the average size of all the particles used is preferably at least about 100 micrometers. More preferably the average size of the particles is between about 100 and 1000 micrometers, and most preferably between 200 micrometers and 500 micrometers.
  • the polymer particles 24 are preferably randomly and widely distributed throughout the sheet 20 to provide good cut-resistance and shred-resistance to the sheet. Such a dispersion provides a high probability that a cutting utensil contacting one of the surfaces 26 or 28 will make contact with one or more of the tough particles 24, thereby reducing the risk that the absorbent substrate 22 will cut or shred in response to the force of the cutting utensil. Particles 24 beneath the cutting surface 26 or 28 can also help minimize cutting and/or shredding of the absorbent substrate 22.
  • the polymer particles 24 are preferably located in fairly discrete areas of the structure, to thereby allow for large areas of the absorbent substrate 20 to be exposed on surfaces 26 and 28 to absorb fluid.
  • the sheet material 20 preferably has a relatively, high basis weight. For example, basis weights of at least 100 pounds per 3000 ft 2 (163 g/m 2 ) are preferred to provide adequate cut-resistance and absorbency. More preferably, the basis weight of the sheet material 20 is at least 165 pounds per 3000 ft 2 (268 g/m 2 ), and most preferably the basis weight of the sheet material is at least 300 pounds per 3000 ft 2 (488g/m 2 ). Also, the sheet material 20 preferably has a thickness t of between about 250 microns (0.01 inch) and about 1270 microns (0.05 inch) to provide adequate cut-resistance and absorbency. If paper making processes and machinery are used to produce the sheet 20, manufacturing parameters such as material application rate, wire rate, amount and duration of pressure applied, etc. can be adjusted to manipulate the basis weight and thickness of the resulting sheet 20.
  • the densified sheet material 20 can be combined with one or more similar or differing layers, to produce a layered structure 21 having advantages of the various layers.
  • the sheet material 20 can be attached to a backing layer 30 to create a multi-layer sheet 21.
  • the backing layer 30 may be formed from any material or materials suitable for attaching as a layer or coating to the sheet 20. Suitable materials include polymeric films, thermoplastic resins, clay coatings, paperboards or metallic foils.
  • the backing layer 30 can comprise one integral layer of material, or a laminate structure having multiple layers of the same or differing composition.
  • the backing layer 30 may also have a high coefficient of friction so as to provide skid resistance, or a non-skid surface, to the sheet structure 21.
  • the backing layer 30 preferably has a static coefficient of friction of at least about 0.4, and more preferably a coefficient of friction of at least 1 with respect to the support surface (e.g., countertop) to provide a corresponding slip angle of around 45 degrees.
  • the backing layer 30 is preferably fluid impervious to resist the escape of fluid from the sheet 20, thereby avoiding contamination of the countertop during use.
  • the layer 30 can be bonded or laminated to the sheet material 20, extruded or thermo-formed onto the sheet 20, or printed, sprayed, adhered, coated, hot-pressed, or otherwise applied to the sheet 20.
  • a hot band press system can be utilized for applying a layer, such as the backing layer 30, to the cut-resistant and absorbent sheet 20.
  • such a hot band press system can also be used for densification of the sheet 20 to increase its cut-resistance and shred-resistance, and/or to cause the polymer particles in the sheet 20 to bond to and/or partially lock around the absorbent material of the sheet.
  • FIG. 14 An example of an embodiment of a hot band press system 91 is illustrated in FIG. 14.
  • an undensified sheet 20 may be fed from a spool or roll 72A, and the backing layer 30 can be fed from a spool 72B.
  • Release paper 90 can be fed from spools 72C and 72D to cover the outward facing surfaces of the sheet 20 and the layer 30, to prevent the sheet and layer from sticking to the hot press 91.
  • the four layers (90, 20, 30 and 90) are fed together through the hot press 91 to bond or laminate sheet 20 with backing layer 30, and also to densify the sheet 20, locking the polymer particles into the sheet.
  • the hot press 91 includes a pair of heated rollers 92A and 92B which move a steel belt 94A and transfer heat thereto. Likewise heated rollers 92C and 92D move and heat steel belt 94B. The four layers are heated and pressed between the two belts 94A and 94B and are moved therebetween to form the layered material 21, which can be taken up on a spool 72E.
  • the release papers 90 can be rewound on rewind rollers 93A and 93B.
  • the backing layer 30 is used in the exemplary implementations shown in FIGS. 3, 4 and 14, it is not necessary to include the backing layer.
  • the sheet material 20 can be densified alone using the system of FIG. 14, and then used as a densified sheet having no backing layer.
  • FIGS. 1-2, 5-8, and 11-12 are shown without a fluid impervious backing layer 30, it should be understood that any of these embodiments could be provided with such a layer to increase skid resistance and/or resist the escape of fluid from the sheet materials 20.
  • a top layer 34 may be laminated, coated, bonded, flocked, or otherwise applied to the first surface 26 of the sheet 20, to create a multi-layered sheet structure 21.
  • the top layer 34 can comprise a surfactant to increase the rate of absorption of fluid into the sheet 20. The use of such a surfactant may allow for higher amounts of polymer 24 in the sheet 20 without sacrificing absorbency.
  • the layer 34 could comprise a treatment layer to reduce shredding of the product. Starch, polyvinyl alcohol, or other sizing agents could be utilized for this purpose.
  • the layer 34 could also comprise an application of surfactant, antibacterial agent, deodorizing agent, or clay coating.
  • a pattern, design, or indicia could be applied thereto.
  • a pattern may be embossed, printed, pressed, or otherwise applied to an exterior surface 26 of the sheet 20 (if used without any additional layers) or to the exterior surfaces of any layer (e.g., layers 30 or 34) which may be applied to the sheet 20.
  • an absorbent layer 32 can be provided between the backing layer 30 and the sheet material 20.
  • the absorbent layer may be formed from any material or materials suitable for absorbing and/or containing the fluids of interest. For example, natural and/or synthetic fibers, absorbent foams, absorbent gelling materials, hydrogels, paper fluff, and other materials could be utilized. Because such an additional absorbent layer 32 can absorb and sequester fluids from the sheet material 20, the sheet 20 can be made less absorbent and more cut and shred resistant by increasing the percentage by weight of particles 24 in the sheet. Moreover, juices produced by the item placed on the top layer 34 can be pulled into the absorbent layer 32, thereby spacing the item from the juices.
  • sheet materials 20 such as those of FIG. 1 can be laminated, bonded, or otherwise adhered to like sheet materials 20.
  • Such a configuration of layering two sheet materials 20' and 20" to form a multi-layered sheet 21 is shown in FIG. 5.
  • the resulting layered sheet 21 may have higher cut resistance when compared to the single sheet materials 20' and 20".
  • cut-resistant particles 24 in the sheet 20' are less densely distributed than the cut-resistant particles 24 of the sheet 20".
  • the lower sheet 20' can provide more absorbency than the upper sheet 20
  • the upper sheet 20" can provide more cut resistance and shred resistance than the lower sheet 20'.
  • FIG. 6 illustrates another embodiment of a layered sheet 21, wherein the sheet material 20 is combined with an absorbent layer 32.
  • the absorbent layer 32 can comprise any suitable absorbent material, such as those absorbent materials mentioned above for example.
  • the cut resistance and shred resistance of the sheet material 20 can be increased by increasing the percent weight of the particles 24 in the sheet.
  • particles 24 can comprise polymer or compounded polymer material and can be provided in an amount of about 50 percent by weight of the sheet material 20.
  • the resulting sacrifice in the absorbency of the sheet material 20 is significantly compensated by the addition of the absorbent layer 32.
  • the absorbent layer 32 can be used to draw fluid from the surface 26 of the sheet material 20, on which food items may be placed for cutting. Accordingly, the multi-layer sheet structure 21 can exhibit high cut resistance and high absorbency.
  • FIG. 7 illustrates another embodiment of a multi-layered structure 21 which utilizes a sheet material 20 made according to the present invention.
  • a cut-resistant backing layer 31 is laminated, bonded, coated, or otherwise applied to the sheet material 20 to form the structure 21.
  • the backing layer 31 can comprise a cut-resistant material, such as a polymeric material. Because the sheet material 20 is combined with the cut resistant layer 31, the percent by weight of the polymer particles 24 in the sheet material 20 can be decreased to thereby increase the absorbency of the sheet material 20. For example, polymer particles 24 can be provided in an amount of about 10 percent by weight of the sheet structure 20. The resulting decrease in cut-resistance of the sheet material 20 is significantly compensated by the cut-resistance of the backing layer 31.
  • the backing layer 31 is also preferably skid resistant and fluid impervious.
  • FIG. 8 illustrates an embodiment of a sheet material 20, where the cut-resistant particles 24 are provided in a plurality of densities.
  • smaller and less dense particles 24' are provided in addition to larger and more dense particles 24".
  • the overall weight of the combination of the particles 24' and 24" is preferably between about 10 per cent and about 50 per cent of the total weight of the sheet material 20. Because the particles 24" are more dense than the substrate 22, they tend to gravitate toward the first surface 28 of the sheet material 20 during formation thereof. Likewise, because the particles 24' are less dense than the substrate 22, they tend to form near the second surface 26 of the sheet material 20 during formation thereof. Accordingly, the sheet material 20 may exhibit a higher absorbency rate when the fluid is provided on the second surface 26 than when the fluid is provided on the first surface 28. However, the first surface 28 may exhibit a higher cut resistance than the surface 26. Thus, the first surface 28 may be used to prepare food items, while the second surface 26 may be placed on a supporting surface, such as a kitchen countertop.
  • FIG. 11 Another variation of such an embodiment is illustrated in FIG. 11.
  • the particles 24 are distributed in a gradient across the thickness t of the sheet 20. More particles 24 are located near the surface 28 than are located near the surface 26. This can be accomplished in a variety of ways in the formation process, such as, for example, by using particles 24 which are more dense than the absorbent 22. Thus, the absorbency and cut resistance vary across the thickness t of the sheet 20.
  • FIGS. 9 and 10 illustrate exemplary equipment and processes for producing the sheet 20 according to principles of the present invention.
  • an undensified sheet material 20 is manufactured using paper making equipment 51, and a densification process is subsequently conducted to better lock the polymer particles into the sheet material and to produce a densified sheet material 20' having increased cut and shred resistance.
  • cellulose fibers in solution are supplied from a chest 50, and polymer particles in solution are supplied from a chest 52.
  • the materials travel through chutes 54 and 56 and into a mixing chamber 58 where the materials are further blended with water to form an aqueous dispersion.
  • the mixing chamber 58 includes an agitator 60 to assist in the blending process.
  • the slurry is then fed from the mixing chamber and through a headbox 62, from which it is fed onto a wire belt 64 or screen where it forms a wet sheet 20.
  • the polymer particles are large enough to be restrained from falling through the wire belt 64.
  • water from the sheet can fall through the wire belt 64 as it begins to dry.
  • Further drying can be achieved by feeding the sheet through press rolls 66 to mechanically remove water in the sheet or through a vacuum to suction water from the sheet.
  • the sheet 20 can be supported on a woolen felt when moved through the press rolls 66. Dryer rolls 68 can then apply heat to the undensified sheet 20 to accomplish further drying by evaporation.
  • rolls 70 In subsequent densification processing, it is preferred that additional heat and/or pressure are applied by the rolls 70, to cause the polymer particles to flow and thereby be further locked into the sheet.
  • rolls 70 could comprise a series of rolls, such as a calendar stack, to lock the particles into the sheet.
  • a heated band press could also be utilized for the densification process.
  • the resulting dried and densified sheet 20' can then be wound on a spool 72.
  • FIG. 10 illustrates air-laying equipment which can also be used to produce the sheet 20 according to principles of the present invention.
  • the cellulose fibers and polymer particles are provided via hopper 82 where they are blown through a chute 84 into an air-laying drum 86.
  • the drum 86 the cellulose fibers and polymer particles are throughly mixed and blended.
  • the mixture is then fed through an air-blow-off plenum 88 and formed onto a belt 80.
  • rollers 70 can be used to apply heat and/or pressure to the formed sheet 20 to allow the polymer particles to flow and become locked into the sheet.
  • a spool 72 can then be utilized to wind the sheet material 20.
  • FIG. 12 illustrates another alternative layered sheet 21, made according to principles of the present invention.
  • the layered sheet 21 comprises a top layer 36, a bottom layer 37, and an absorbent and cut-resistant sheet material 20.
  • the sheet material 20 includes an absorbent substrate 22 and cut-resistant polymeric particles 24.
  • the substrate 22 and particles 24 can be made from one or more of the exemplary materials described above.
  • the substrate 22 preferably comprises cellulosic material and the particles 24 preferably comprise polymeric material.
  • the particles have an average size of at least about 100 micrometers, and the absorbent substrate 22 is substantially free of any inorganic filler and provided in an amount of at least 50 percent by weight of the sheet 20.
  • the basis weight of the sheet 20 is preferably at least 100 pounds per 3000 ft 2 (163g/m 2 ), and most preferably around 250 pounds per 3000 ft 2 (406 g/m 2 ).
  • the top layer 36 and bottom layer 37 are preferably free of polymeric particles, and can be made of any material capable of substantially covering the surfaces 26 and 28 of the sheet 20, to thereby restrain particles 24 from becoming freed from the sheet 20 during manufacture.
  • the top layer 36 and bottom layer 37 can be made from paper, paper-board, paper-like materials, or non-woven materials. It has been found that when particles 24 become detached or freed during manufacture of a sheet 20, they may stick to or melt on various parts of the manufacturing equipment. Accordingly, it is desirable to provide one or more components which assist in retaining the particles 24.
  • the layered structure 21 of FIG. 12 is one preferred configuration for retaining the particles 24 within the sheet 20. Other methods and/or components could be utilized in addition to or as alternatives to use of the layers 36 and 37.
  • a retention agent or aid could be included within the sheet 20 to further assist in locking the particles 24 within the sheet 20.
  • the layers 36 and 37 could enhance other properties of the sheet, such as appearance and performance properties for example, after the sheet is manufactured.
  • the layers 36 and 37 can be bonded or laminated to the sheet material 20, extruded or thermo-formed onto the sheet 20, or printed, sprayed, adhered, coated, pressed, or otherwise applied to the sheet 20. Moreover, the layers 36 and 37 can each comprise one integral layer of material, or a laminate structure having multiple layers of the same or differing composition.
  • FIG. 13 illustrates a potential method for manufacturing the layered structure 21 of FIG. 12 using conventional paper manufacturing equipment 51, such as equipment which manufactures paper or paperboard, for example.
  • cellulose fibers in solution are continuously provided through headbox 162 onto the wire screen or mesh 64 to form the lower layer 37.
  • a cellulose and polymer particle slurry is continuously fed through the headbox 164 on top of the layer 37 to form the layer 20.
  • cellulose fibers in solution are continuously provided on top of the layer 20 to form the top layer 36.
  • the undensified layered structure 21 can be fed through one or more dryer rolls 68 to complete the drying of the structure.
  • the three layers 36, 20, and 37 which make up the structure 21 can then be bonded, pressed or laminated together to form a densified layered structure 21'.
  • a plurality of heated rolls 66 and 66' can be provided, such as are utilized in a calendar stack.
  • the structure 21 can be pressed and heated between the rolls 66 and 66', to cause the polymer particles to be locked into the structure, and to form the densified structure 21', which can then be collected on a spool 72.
  • the top and bottom layers 36 and 37 are each significantly thinner than the sheet 20, and have a significantly lower basis weight than the sheet 20.
  • the layers 36 and 37 can each be provided at a basis weight of about 35 pounds per 3000 ft 2 and the sheet 20 can be provided at a basis weight of about 250 pounds per 3000 ft 2 (406 g/m 2 ).
  • each of the layers 36 and 37 contribute between about 10 to 25 percent of the basis weight of the resulting layered structure, with the middle layer contributing between about 50 to 80 percent of the basis weight.
  • the manufacturing equipment can be chosen to accommodate particles which may stick to the equipment.
  • the equipment can be provided with blades, such as doctor blades, to periodically scrape material from rolls or other components.
  • the components such as the dryer rolls for example, may be coated with a non-stick finish, such as Teflon for example, to prevent material from building up.
  • the equipment can use air floatation devices to prevent the sheet material 20 from contacting components. Processing the sheet material 20 at lower heat may also prevent the polymer particles 24 from melting and sticking to the equipment.
  • Sheet materials made according to the present invention will be further illustrated by the following examples.
  • the listed type, size, and amount of polymer particles are mixed with the listed type and amount of cellulose materials.
  • the mixture is sufficiently blended with water to provide random and substantially wide distribution of the particles and paper fibers.
  • the aqueous dispersion is applied to a wire screen to allow the water to drain therethrough leaving a moist mat of paper and polymer particles on top of the screen.
  • the mat is then dried to remove remaining moisture. Once dried, the cellulose fibers bond with one another, as known in the art.
  • the resulting undensified sheet is then subjected to the listed temperature and pressure in a heated platen press for the duration indicated, to allow the polymer to flow somewhat and more securely bond to the cellulose substrate, and to densify the structure for increased cut and shred resistance.
  • Suitable paper materials could be utilized, including NSK fluff, eucalyptus, chemithermomechanical pulp (CTMP), and thermomechanical pulp (TMP) for example.
  • CTMP chemithermomechanical pulp
  • TMP thermomechanical pulp
  • one or more layers can be added to the sheet structure to enhance performance or provide other properties.
  • a backing layer can be applied to the sheet material to resist the escape of fluid and provide a skid resistant surface.
  • Dyes can be added to the paper or the polymer or the mixture thereof, to make the resulting sheet more visually appealing. For example, dyeing the paper or the polymer can produce a marble-like appearance. Additives can also be used to improve the dispersion of the polymer particles throughout the paper.
  • surfactant for instance, surfactant, retention aids, drainage aids, deposit control agents and the like could be added.
  • other additives such as antibacterial substances and deodorants for example, could also be added to the mixture.
  • use of loose filler fiber and particulates, such as inorganic particulate for example, in the absorbent substrate is preferably avoided, as such fillers could shred during use of the sheet and contact food being prepared and limit absorbency. Use of fillers in the polymer particles themselves should not present this problem, however.
  • a continuous band press could be utilized to densify the sheet material.
  • the finished sheet can receive additional types of treatment after being formed.
  • the sheet could be embossed or printed with a design to make the sheet more visually appealing.
  • the sheet may be combined with additional materials to improve shred resistance, if desired, and cut to the desired size and shape.
  • samples 1-3 and 5-6 describe inventive absorbent sheet materials having cut-resistant particles. All examples use 0.75% by dry paper weight of Kymene 557LX, a wet strength agent manufactured by Hercules, Inc.
  • Southem softwood kraft (SSK) and eucalyptus (Euc) drylap are defribillated in water to produce a slurry.
  • the paper fiber is blended in a ratio of about 75% SSK to 25% Euc.
  • the mixture is then run on a Fourdrinier-type linerboard machine, to produce rolls ofundensified paper with basis weight of about 320 lb/3000 ft 2 (520 g/m 2 ).
  • the paper is subsequently cut into sheets and subjected to a densification process to improve the cut resistance and shred resistance of the base paper.
  • the sheets are pressed in a hot platen press at 380°F (193°C) and 440 psi (30336 kPa) for 25 seconds.
  • SSK drylap is defibrillated in water to produce slurry A.
  • SSK and eucalyptus drylap are defribillated in water to produce slurry B.
  • the paper fiber of slurry B is blended in a ratio of about 75% SSK to 25% Euc.
  • PETG 6763 particles(from Eastman Chemical), cryogenically ground on an attrition mill to an average particle size of approximately 300 microns, are added to slurry B.
  • the particulate material is added at about 38% by weight of the total mass (paper+particulate) in slurry B.
  • a three-ply product is produced with the top and bottom layer produced from slurry A and the middle layer produced from the particulate loaded slurry B.
  • Rolls of undensified three-ply paper are produced with a total basis weight of about 320 Ib/3000 ft 2 , where the top and bottom layers each have a basis weight of about 35 Ib/3000 ft 2 .
  • the overall polymer concentration of the sheet is about 30% (by weight).
  • the paper is subsequently cut into sheets and subjected to a densification process to improve the cut resistance and shred resistance of the base paper, wherein the sheets are pressed in a hot platen press at 380°F (193°C) and 440 psi (30336 kPa) for 25 seconds.
  • SSK and eucalyptus drylap are defribillated in water to produce a slurry.
  • the paper fiber is blended in a ratio of about 75 % SSK to 25% Euc.
  • PETG 6763 particles (from Eastman Chemical), cryogenically ground on an attrition mill to an average particle size of approximately 220 microns, are added to the slurry.
  • the particulate material is added at about 30% by weight of the total mass (paper+particulate).
  • the mixture is then run on a Fourdrinier-type linerboard machine to produce rolls of undensified paper with basis weight of about 320 lb/3000 ft 2 (520 g/m 2 ).
  • the sheets are pressed in a hot platen press at about 380°F (133°C) and 440 psi (30 336 kPa) for about 25 seconds.
  • Southern softwood kraft (SSK) and eucalyptus drylap are defribillated in water to produce a slurry.
  • the paper fiber is blended in a ratio of about 75% SSK to 25% Euc.
  • the mixture is then run on a Fourdrinier-type linerboard machine produce rolls of undensified paper with basis weight of about 320 1b/3000 ft 2 .
  • the paper is subsequently cut into sheets and subjected to a densification process, wherein the sheets are pressed in a hot platen press at about 380°F (193°C) and 440 psi (30336 kPa) for about 25 seconds
  • Southern softwood kraft (SSK) and eucalyptus drylap are defribillated in water to produce a slurry.
  • the paper fiber is blended in a ratio of about 75% to 25% SSK to Euc.
  • PETG 6763 particles (from Eastman Chemical), cryogenically ground on an attrition mill to an average particle size of approximately 300 microns, are added to the slurry.
  • the particulate material is added at about 30% by weight of the total mass (paper+particulate).
  • the mixture is then run on a Fourdrinier-type linerboard machine to produce rolls of undensified paper with basis weight of 200 lb/3000 ft 2 (325 g/m 2 ).
  • the paper is subsequently cut into sheets and subjected to a densification process to improve the cut resistance and shred resistance of the base paper.
  • the sheets are pressed in a hot platen press at 380°F (193°C) and 440 (30336 kPa) psi for 25 seconds.
  • SSK and eucalyptus drylap are defribillated in water to produce a slurry.
  • the paper fiber is blended in a ratio of about 75% SSK to 25% Euc.
  • PETG 6763 particles (from Eastman Chemical), cryogenically ground on an attrition mill to an average particle size of approximately 200 microns, are added to the slurry.
  • the particulate material is added at about 30% by weight of the total mass (paper+particulate).
  • the mixture is then run on a Fourdrinier-type linerboard machine to produce rolls of paper with basis weight of about 165 lb/3000 ft 2 .
  • the undensified paper is then cut into sheets and subjected to a densification process to improve the cut resistance and shred resistance of the b e paper.
  • the sheets are pressed in a hot platen press at about 380°F (193°C) and 220 psi (15168 kPa) for about 25 seconds.
  • the test apparatus described applies a known force in the z (vertical) direction on a knife blade to measure the cut resistance of a sample.
  • a knife blade is placed in the knife holder.
  • the knife blades used for all testing are Poultry Blades Code # 88-0337 by Personna.
  • the test sample is mounted to a sample platform.
  • the knife blade is then brought into contact with the sample.
  • a known load is applied to the knife blade in the vertical direction.
  • the sample platform is then moved at a rate of 8 inches per second for 4 inches under the weight of the knife blade creating a slice.
  • Consecutive slices of increasing load are made until the knife blade cuts through the sample.
  • the knife force required to penetrate completely through the sample is recorded.
  • Slice resistance is calculated as the slice force / sample thickness. Replicate test on 3-5 separate samples and report average values.
  • Sheet materials having cut-resistant particles and made in accordance with the present invention exhibit high absorbency, high cut-resistance, and low abrasion loss.
  • the absorbent efficiency, slice resistance, and abrasion loss for SAMPLES 1-6 are indicated in the table of FIG. 15.
  • sheet materials made according to principles of the present invention preferably exhibit an absorbent efficiency of at least about 0.2 and a slice resistance of at least about 30 kgf/cm. It is preferred that the inventive sheet materials exhibit an absorbent efficiency of at least about 0.2 and that the cutting surface of the sheet materials exhibit a wet abrasion loss of less than about 400 mg per 100 revolutions, and more preferably less than about 300 mg per 100 revolutions.
  • the sheet materials of the present invention exhibit an absorbent efficiency of at least about 0.2, a slice resistance of at least about 30 kgf/cm, and a wet abrasion loss of less than about 400 mg/100 revolutions. Even more preferably, the sheet materials of the present invention exhibit an absorbent efficiency of at least 1.0, a slice resistance of at least 40 kgf/cm, and a wet abrasion loss of less than about 400 mg per 100 revolutions.
  • the cutting surface of such a material also preferably exhibits a dry abrasion loss of less than about 300 mg per 100 revolutions and more preferably less than about 200 mg per 100 revolutions.
  • the absorbent material within the sheet is provided in amounts of at least 50 percent by weight, in order to provide good absorbency, and that the cut-resistant particles are provided in an amount of between about 10 percent and about 50 percent by weight of the sheet.
  • the sheet material also preferably has a relatively high basis weight. For example, weights of at least 100 pounds per 3000 ft 2 (0.016 g/cm 2 ) are preferred to provide adequate cut-resistance and absorbency.
  • the basis weight of the sheet material is at least 165 pounds per 3000 ft 2 (0.027 g/cm 2 ) and most preferably the basis weight of the sheet material is at least 300 pounds per 3000 ft 2 (0.049 g/cm 2 ).
  • the sheet material preferably has a thickness t of between about 250 microns (0.01 inch) and about 1250 microns (0.05 inch) to provide adequate cut-resistance and absorbency.
  • the particles in the inventive sheet material preferably comprise a polymeric material, and preferably have an average size of at least about 100 micrometers (microns), and most preferably between 200 micrometers and 500 micrometers.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Laminated Bodies (AREA)
  • Paper (AREA)
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EP01932655A 2000-04-27 2001-04-25 Absorbent sheet material having cut-resistant particles and methods for making the same Expired - Lifetime EP1276610B1 (en)

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US560068 2000-04-27
US09/560,068 US6592983B1 (en) 1999-06-18 2000-04-27 Absorbent sheet material having cut-resistant particles and methods for making the same
PCT/US2001/013455 WO2001080801A2 (en) 2000-04-27 2001-04-25 Absorbent sheet material having cut-resistant particles and methods for making the same

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DE60122313T2 (de) 2007-08-23
AR028051A1 (es) 2003-04-23
MXPA02010653A (es) 2004-05-17
ATE336368T1 (de) 2006-09-15
DE60122313D1 (de) 2006-09-28
CA2403712C (en) 2007-03-27
PL357767A1 (en) 2004-07-26
BR0110379A (pt) 2003-07-29
NZ521941A (en) 2004-07-30
KR20020089576A (ko) 2002-11-29
JP2003531308A (ja) 2003-10-21
US6592983B1 (en) 2003-07-15
CA2403712A1 (en) 2001-11-01
ES2271007T3 (es) 2007-04-16
KR100644109B1 (ko) 2006-11-10
AU2001259164A1 (en) 2001-11-07
WO2001080801A3 (en) 2002-04-04
ZA200208068B (en) 2003-05-13
EP1276610A2 (en) 2003-01-22
WO2001080801A2 (en) 2001-11-01

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